Over the past few decades, Forge div which was a captive unit of Tata Motors Ltd. has seen many ups & downs w.r.t product portfolio. As a forging supplier, we had catered Tata Motors Ltd. for its M&HCV requirements like :

Just because of our strategic needs of our M&HCV business, we have confined our forging business with components which are more critical to quality like Front Beams, Crank Shafts, Stub Axles and Rear Axle Shafts. Soon after its amalgamation with TML Drivelines Ltd., which is 100% subsidiary unit of Tata Motors Ltd., the unit is now capable of producing low cost transmission solution for in-house as well as global customers.

Together with TML Drivelines Ltd. we can offer end-to-end transmission solutions to global customers, based on its extensive technology, product design and product development expertise.

FORGING FACILITIES:

We are into the business of closed die forging using both Hammer as well as Press technology with all related infrastructural facilities to produce quality forgings from our existing 4 forgings lines with combined capacity of 20, 000 TPA. As of now we are supplying forgings to our own Axle division of TML Drivelines ltd & Engine division of Tata Motors Ltd.

Over the past few years, we are under transformation and upgrading our facilities to meet customer demand without compromising with our values like customer, innovation, concern for environment, passion for excellence and agility to change.

Some of the major milestones are:

  • Upgrading the material handling facility likes Robotics in place of rotary manipulators and servo pneumatic overhead gantry system for positive material transfer to achieve positional placement accuracy within the dies and tools.
  • Changing the mode of billet heating from oil fired heating to propane fired heating & induction billet heating.
  • Allocating and spending significant amount of its overall annual budget for implementing SAFETY inside works with Du-pont as consultant.
  • TML Drivelines Ltd proved its loyalty for the land & people where it is operating like its mother unit by implementing these projects even in the crisis because of global economic recession & bonded to our core values.
  • We are putting our continuous effort for making our forging lines are highly flexible, which gives the company the inherent advantage to meet different customer demands and optimize capacity utilization. This will allow TML Drivelines Ltd to meet the growing demands of its customers continuously.

HEAT TREATMENT FACILITIES:

Our in-house Heat Treatment Capabilities enhance the total control over the manufacturing of quality forgings. The facility is capable of most of the required operations for our in house production and has performed various requirements for specific heat treat needs for our customer Tata Motors Ltd.

Our Heat Treatment facility includes continuous moving furnace, induction heating furnaces, bogie hearth furnace, rotary hearth furnace & batch furnaces, all with designed to The Finishing Shop has shot blasting machines, coining and painting facilities. The heat treatment facilities at Bharat Forge also include control cooling for micro-alloyed steels.

FACILITY INCLUDES:

  • 4 Ton per hour continuous Quench and Temper Automated line with polymer quenchant.
  • 4 Lbs. per hour continuous Quench and Temper Automated line with polymer quenchant
  • 5 Nos. of Continuous moving heating furnaces.
  • 4 Lbs. per hour stress relieving furnaces.
  • One Bogie hearth furnace.
  • 1250 Kw induction heating furnace.
  • 3000 Kw induction heating furnace.
  • 3 box type batch furnaces.

TESTING FACILITIES:

Forge Division has full range of Testing & Inspection Facilities like :

1. CMM Marking M/c

2. Magnaflux Testing M/c's

3. Metallurgical Laboratory

4. Spark Testing M/c

5. Dedicated Gauges, Fixtures etc.

DESIGN & DEVELOPMENT FACILITIES:

The ENGG & RESEARCH CENTRE processes are well-designed to adopt best practices and technology, and to continuously improve upon them to meet the growing challenges.

  • State-of-the-art CAD/ CAM/ CAE infrastructure for 3D modeling, NC tool path generation and FEA analysis to accelerate response time in developing new parts.
  • Metal flow simulation software "DEFORM" for virtual manufacturing for design optimization and process validation to develop new parts right the first time.

PROCESSING FACILITY:

The processing lines of Forge comprises of all post finishing operations like Shot Blasting, Straightening, Magnetic Particle Inspection, Grinding, Finishing and Painting/ Rust preventive applications. This division has world class machines such as multi impeller, spinner hanger type & table type shot blasting machines from world leader like, Pangborn. With an objective to meet world class customer requirements, the company has set up a state-of-the-art processing facility including online gauging facilities for Front axle beams, Crankshafts, Steering Knuckles, & Rear Axle shaft.

The Magnetic Particle Inspection facility specially designed to meet customer requirements with AC & DC current type and multidirectional magnetism facilities has a capacity of up to 8000 Amps. The experienced manpower in the processing line is qualified for MPI-ASNT Level II certification, which is a mandatory requirement for customers all over the world. The facilities also include dip painting system with drying facility for painting. With these systems in place all specific customer requirements are fulfilled.

PRESENT FACILITIES

KURIMOTO LINE FOR F A BEAM 6000 T MAXI PRESS FOR STUB AXLE BOFCO HEAT TREATMENT FURNACE :
4 TONS/HR
N- LINE FOR CRANKSHAFT 5" UPSETTER FOR REAR AXLE SHAFT F A BEAM SETTING
F A BEAM SHOT BLASTING F A BEAM FINISHING STUB AXLE & CRANKSHAFT SHOT BLASTING

NEW INSTALLATION

NEW 2100 T COMBINED TRIMMING & COINING PRESS AT FORGE
100 T COMBINED TRIMMING & COINING PRESS
ADD ON FEATURES OF PRESS
Mechanical Press with Double crank
Permissible Force (Max) - 2100 Ton
FANUC Make Robots - 2 nos.
Gerlieva Make Die lubricant system
Quick die change system with hydraulic clamping arrangement
 

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